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Basics of Rolling Mill Guide Design

By

Morgan Construction Company - A Siemens Company Worcester, MA 01605 USA

Contents

Introduction Long rolling mill guide design parameters Restbars and other ancillaries Optical alignment equipment Rod finishing mill guides

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SVAI Long Rolling (LR) Services: Spares, Guides, Upgrades & Services Global Organization: Morgan Worcester Siemens VAI Italy (Pomini) Morgan India Morgan Shanghai Siemens VAI UK (Ashlow Morgan Europe) Siemens VAI Brazil (Morgan do Brazil) and the other Siemens VAI Service locations throughout the world With this expanded network we can be even closer to customers to support all activities and requirements

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SVAI Long Rolling Services A growing global organization focused on the needs of all rolling mills MAINTENANCE REBUILDS RECONDITIONING

SPARES

TRAINING Mission: Maximize Mill Utilization

UPGRADES

SERVICES

GUIDES

AUDITS

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Guide Equipment

It all started in 1879 with the first of many patents from Company founder Charles Hill Morgan Together with Siemens VAI guides (Ashlow) we offer the most expansive guiding solutions of any guide supplier in the industry

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Siemens VAI guides

Main benefits:

Highest competitiveness Quick and simple adjustment Minimum maintenance requirements Long operational service life

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Siemens VAI guides

Our vast guide portfolio covers the following applications and more.... Applications: including but not limited to rounds, rebars, flats, squares, hexagons and angles Also providing:
Restbars Interstand loopers and guiding Air/oil lubrication systems Optical setting equipment Water cooling headers High-speed flaw detector guides

Leading technology in multi-slit rolling with over 40 references worldwide


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Guide Design and Rolling The Basics of Guide Design Agenda Basic Rolling Requirements
It all starts in the Roll Shop

Basics of Guide Design


Equipment design and operating parameters

General Guide Topics


Types of guides, considerations etc.

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Basic Rolling Requirements


Conventional Rolling Stands
Mill Roll Groove Pass Alignment
A program for mill roll pass groove preparation and roll tracking is required Together is standard practices the rolls and stands are consistently prepared for the rolling mill The productivity of the rolling mill is directly related to the roll shop

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Basic Rolling Requirements


Conventional Rolling Stands
Restbar and Saddle Alignment
The restbar elevation and position must be properly set and maintained Premature guide failures and increased wear can be a result of poor restbar design or condition Poor positioning results in hooked front ends, cobbles, and guide failures

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Basic Rolling Requirements Restbar and Saddle Alignment Mechanical tools for checking alignment

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General Guide Topics Restbars and Guide Mountings Restbar designs must be durable and provide years of accurate location of guides Mounting and clamping surfaces must be maintained Adjusting restbars must be rebuilt and maintained for correct operation Secondary adapter plates and fine pass adjustment bases can be used for smaller guides or guides requiring more location accuracy

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Restbars & Guide Mounting Equipment Traversing and fixed restbars Guide mounting adapter plates Fine-pass adjusting bases

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Basic Rolling Requirements Conventional Rolling Stands Stand alignment to interconnecting equipment
Proper alignment through all areas of the mill must be maintained Premature guide failures and increased wear can be a result of poor alignment Forcing equipment out of position is not sound rolling practice

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Basic Rolling Requirements


Conventional Rolling Stands
Roll Groove Cooling
Pass design, guide design, and cooling header design all must be considered together for proper roll cooling Advances in materials and methods for mill roll manufacture demand increased awareness and optimization of roll cooling designs Proper roll cooling reduces pass wear, increases product quality and mill utilization and decreases operating costs Typical Static Delivery Guide With-Header Twist Delivery Guide With-Header

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Basic Rolling Requirements Conventional Rolling Stands Roller guide cooling and lubrication
Review of the piping and systems for applying the roller cooling and bearing lubrication is required before and during the guide service time in the mill Failure to monitor the roller cooling and bearing lubrication directly causes roller and bearing failures and cobbles

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Basic Rolling Requirements Cantilevered Rolling Stands Mill roll groove alignment
Mill roll grooves must be properly cut and inspected Mounting sleeves and tooling must be inspected and proper procedures followed Some variables can be reduced with adjustments to the guiding equipment

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Basic Rolling Requirements Cantilevered Rolling Stands Roll housing preparation and condition
A schedule for maintenance must be created Inspection and proper procedures must be followed to maximize the equipment life Damaged or worn housings can result in increased guide delays and operating costs

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Basic Rolling Requirements Cantilevered Rolling Stands Bracket and saddle alignment
Mounting brackets rigidly align and hold the guides to the roll housing The mounting surfaces and clamping equipment must be free of damage and scale A schedule for maintenance must be created and spare parts available

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Basic Rolling Requirements Cantilevered Rolling Stands Roll cooling and pass life
The design requirements for roll cooling increases with mill roll hardness and rolling speed Roll cooling headers need to be inspected regularly at mill roll and guide changes Worn, damaged, or poorly designed headers directly affect pass life and product quality

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Basic Rolling Requirements Cantilevered Rolling Stands Flutter and the finishing mill
A great deal of testing of the effects of the flutter related to feed area, steel grade, and temperatures has allowed Morgan to make advances in roll pass design to reduce some of the flutter and produce the highest quality finished product tolerances at the worlds fastest finishing speeds Please contact Morgan Rolling Services for assistance in this area

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Basics of Guide Design Design input requirements for guides (required for all mill locations and installations) Mill roll maximum and minimum diameter Mounting restbar dovetail dimensions and locations from the center of the mill stand The distance from the stand centerline to the interconnecting equipment The distance between the rolling stands The location and design of the mill roll cooling headers The pass groove details of the incoming feed section The pass groove details of the outgoing rolled section

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Basics of Guide Design Design input requirements for guides (contd) The mill roll partings for each pass groove and section rolled The key tolerance and size if the restbar has a key and keyway design The inside dimension of the stand housing window The distribution of passes along the mill roll barrel The dimension from the end of the roll barrel to the mill roll chocks The dimension of the strand centers (for multi-strand mills only)

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Basics of Guide Design Design input requirements for guides (contd) Additional requirements for cantilevered stands only
The dimension of the roll housing to the centerline of strand The location of the pinion bore to the guide mounting location and the dimension of the eccentric throw The design of the seal plate The dimensions for the mounting holes and keyways for guide mounting brackets

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Basics of Guide Design Design input requirements for guides (contd) The main point is that ALL input requirements must be considered when designing and installing guides to get the optimum performance and reliability

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Basics of Guide Design What guides should be supplied? Once all the parameters are gathered a final decision is required to determine what type of guide is required A review of the progression of passes is required to understand the guiding requirements and options

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Basics of Guide Design Stable pass progressions Stable progressions typically do not require secondary support from direct contact guiding Some examples of stable progressions

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Basics of Guide Design Stable pass progression examples

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Basics of Guide Design A few Un-stable pass progression examples

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Basics of Guide Design Review of pass progressions leads to the final decision of the type of guide to be used for the specific application There are many reasons to choose a guide design but all factors and requirements must be reviewed for the correct choice for each rolling location A simple but critical type of guide in the mill is the static receiving guides that deal with a wide variety of stable pass progressions

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Basics of Guide Design Static Receiving Guides Illustration for receiving guide discussion

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Basics of Guide Design Static Receiving Guides The guide bore must be less than the full width on face of that stands work roll pass The guide bore is typically 85-90% of said pass width of face The length of the rifling is typically 2-3 times the guide bore for stability Worn static receiving guides lead to delivery guide cobbles and twist guide failures from hooked and knuckled head ends

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Basics of Guide Design Static Delivery Guides The main function of delivery guides is to ensure the smooth passage of the bar from the rolling stand to the next piece of mill equipment There are two basic guide types: stripper and catcher
Stripper guides are used to minimize hooks Catcher guides are used to reduce change time

The chance of cobbles must be considered with the guide and mounting bracket design to protect the rolling mill stand

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Basics of Guide Design Static Delivery Guides Illustration for delivery guide discussion

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General Guide Topics Roller Entry Guide Designs Two basic guide design types, leaf and block
Both types have design points that must be reviewed for each application and operator preference

Two and four roller guides have specific application points and must be reviewed for each application and operator preference
The back rollers of the 4 roller guide are set slightly larger than the front rollers to promote a rollerized funnel effect

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Basics of Guide Design Roller Entry Guides The main function of the roller entry guide is to prevent the rolled section from rotating in the work roll pass groove Exiting product tolerance is a direct result of durability and accuracy of the guide setting and guide roller and static insert design The static entry insert must minimize the impact on the guide roller and bearings but must not rub on the bar through the length of the billet The guide roller design must be carefully reviewed to maximize roller and bearing life and product quality

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General Guide Topics Roller Entry Guide Roller Design Profile and V-grooves are the two main types For hard-metal mill rolls the profile rollers are preferred and outperform V-groove rollers Both roller types need to be designed to utilize the full operating range of the roller entry guide assembly to provide the maximum payback for the rollers

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General Guide Topics Roller Entry Guide Roller Design Comparison of V-groove versus profile rollers V-groove rollers typically contact at around 65% of W.O.F. Profile rollers should have minimum contact of 75%

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Basics of Guide Design Roller Entry Guides Roller design W.O.F. Contact Assembly capacity Insert clearance Roller parameters

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Basics of Guide Design Roller Entry Guides Insert design with twisting entering section into guide

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Basics of Guide Design Roller Entry Guides (contd) The insert clearances are 15-30% larger than the guided section based on location and speed of the guided section The guide roller needs to support at least 75% of the oval pass width and can approach 100% for the smallest leader ovals for high-speed wire rods Bearing lubrication and guide roller cooling are key to guide life

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General Guide Topics Roller Entry Guide Nosepiece The nosepiece is used to fill the space from the guide roller to the mill roll bite With correct settings and alignment the nosepiece should never be in contact with the rolled section The nosepiece width is typically equal, or nearly equal, to the dimension of the height of the preceding roller entry guide static inserts

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Basics of Guide Design Other Roller Entry Guides The open top 4 roller guide with symmetrically adjusting base provides the flexibility to guide the process passes for flats, channels and angles with only adjustments for width and centering spacer shape A top adjusting three roller guide is often used for angle and channel passes but the guide is limited to longer distances from the roll bite
The main requirement for this guide are for the production of sharp apex angle sections

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General Guide Topics Roller Twist Delivery Guide Designs Four basic guide design types: link, top adjust, outboard, and cassette. Link-style provides design and rolling flexibility Top adjust provides ease of maintenance but limited flexibility Outboard provides ease of maintenance and rolling flexibility but is limited in installation options Cassette design offers strength but increased maintenance and limited installation options All types have design points that must be reviewed for each application and operator preference

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Basics of Guide Design Roller Twist Delivery Guides The main function of the roller twist delivery guide is to apply a force to rotate the rolled bar to the required rotational position for the next rolling stand The delivery guide insert bore must have clearance for the horizontal and twisted section to ensure no rubbing occurs The guide roller shape must consider the guide operating capacity, maximum roller diameter, and point of contact for the application of the twisting force Bearing lubrication and guide roller cooling are key to guide life

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Basics of Guide Design


Roller Twist Delivery Guides
Calculation of twist at the RE guide rollers
X = Distance from stand to stand Z = Distance back from stand to RE guide rollers Y = Distance from stand to Twist guide rollers T = The required twist angle
(see page 33 in guide design document for illustration)

X Z = 90o Y T

Solve the ratio for T where T is the twist angle in degrees

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Basics of Guide Design Roller Twist Delivery Guides Layout of guide rollers Show rolled section at calculated twist angle T Rotate rollers to near maximum guide twist Construct tangent on rolled section at 75% W.O.F. Construct gauge diameter between two guide rollers

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Basics of Guide Design

Roller Twist Delivery Guides


Delivery inserts
Basic design is the same for a delivery guide, either stripper or catcher type The insert must consider the back-twist of the rolled section

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General Guide Topics Guide Roller Bearing Design The proper tools must be used to install any bearings with imparting damage before the bearing is even used Tapered roller bearings for slower speeds and higher load Deep groove ball bearings for higher speeds and longer bearing life Ball bearing spacers must be undamaged to prevent bearing preload when installed

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General Guide Topics Optical Alignment of Guides and Mountings Bench Optics for use in the roll shop Portable Optics for use in aligning restbars and guide mounting brackets System allows for guide life and product tolerances not achievable with mechanical guide setting techniques

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Bench Optics Alignment Equipment


Universal bench optics to setup a large range of roller guides in the roll shop

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Bench Optics Alignment Equipment Provides consistent setting of guides in the roll shop by all operators No variability from operator feel and guesswork using gauge bars or cobbled sections for setup Superior resolution for precise guide setting and increased guide life and product quality Calibration matched to Portable Optics system

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Optical Calibration

Care is taken to calibration match the bench and portable optics to ensure superior precision
Using the same mounting plates and alignment tooling the bench and portable optics are set to the exact same mechanical and optical centerline

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Portable Optics Alignment Equipment Unsurpassed finished product tolerances

Portable optics setting in the NTM


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Clamped on the X-clamp mounting system


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Portable Optics Alignment Equipment Precise positioning of the roller entry guide bracket to the centerline of the roll groove Used as a tool for checking roll cross indicating
Worn flingers in cantilevered mill stands Incorrect pass grinding or re-cutting in the mill rolls Worn tapered sleeves on cantilevered mill stands Worn thrust bearings Incorrect mill roll mounting or positioning

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Portable Optics Alignment Equipment Conditions of roll cross

If crossed rolls are found then proper corrective action procedures must be in place for the operators to make a determination when the billets should be rolled
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Results: Maximum Guide Life RE-20 guide rolling 5,5mm at 18,100ft/minute (92m/s) 5,831 tons rolled

No changes to rollers or bearings Campaign completed with no guide changes

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Specialized Guide Topics Multi-strand Slit Rolling of Rebars The dividing of the billet into 2,3, or 4 bars for the production of multiple finished products in a single strand rolling mill
This is done by using a forming pass design to define to areas of the individual finished strands and slitting the bar using slitting delivery guides or powered slitting machine

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Multi-strand slit rolling of rebars

Powered slitting machine


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3-Strand Slitting guide on the Bench Optics


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Multi-strand Slit Rolling of Rebars

Increased production for smaller finished diameters

10mm Rebar
140.0 120.0 R o llin g R a te (m t/h ) 100.0 80.0 60.0 40.0 20.0 0.0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Finishing Speed (m/s)
1 x 10mm 2 x 10mm 3 x 10mm 4 x 10mm

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Multi-strand Slit Rolling of Rebars Slit rolling pass sequence example

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Multi-strand Slit Rolling of Rebars Slit rolling pass sequence example

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Multi-strand Slit Rolling of Rebars

Higher production of small rebar can be achieved without large capital equipment expenditures The rolling mill can be operated to its full design capacity for the entire product mix The product mix can be expanded to small sizes that were not cost effective to produce via conventional rolling methods Can be easily applied to most bar mill configurations

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Siemens VAI Guides Guides for all mill types.... Recent Guiding Projects:
POMINI Rod and bar mills worldwide MORGAN High speed rod mills worldwide ASHLOW High speed rod mills worldwide SMS DEMAG SIMAC NKK DANIELI SKET VAI Rod mill in Saudi Arabia Bar mill in Saudi Arabia Rod and bar mill in Egypt Bar mill in Egypt Flexi mill in Saudi Arabia Rod mill in Ukraine Bar mill in Kuwait

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Thank You for your time and attention